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Last-mile vehicle: Digital and physical prototyping of high-performance cargo bikes

Publication date: 2024-05-31

Author:

D'hondt, Jordi
Slaets, Peter ; Juwet, Marc ; Demeester, Eric

Abstract:

The Courier, Express and Parcel service sector has experienced consistent growth, primarily attributed to the increasing popularity of E-commerce. In Belgium alone, the year 2020 saw the delivery of 336 million parcels. The last-mile delivery, which represents only a small portion of the travelled distance but approximately half of the logistical chain cost, presents significant challenges. Delivery of on average 0.1 parcels per person daily is primarily done by vans. However, this reliance contributes to pollution and congestion issues in city centres, prompting municipalities to implement measures such as circulation plans, low-emission zones, and car-free zones. To address these challenges, this doctoral dissertation proposes the utilization of cargo bikes as a potential optimization solution for last-mile delivery. Cargo bikes offer advantages such as reduced congestion, the ability to utilize bicycle lanes, easier parking, and a lower ownership costs. Moreover, governments are actively promoting environmentally friendly alternatives. Despite these benefits, cargo bikes face limitations in cargo capacity. To overcome this obstacle, the research introduces a novel cargo bike design, specifically engineered to enhance cargo space and handling qualities. Beginning with a comprehensive market research phase to identify vehicle requirements and assess existing cargo bike models, the development process progresses to prototype creation. The resulting prototype is a three-wheeled vehicle featuring a conventional cyclist module and a cargo area capable of transporting a euro pallet up to 200 kg between the two rear wheels. The design allows for independent tilting of the driver, facilitating manoeuvrability. Propulsion is achieved through an electrical drivetrain system, comprising a pedal generator and two hub motors. A sophisticated control loop is developed to simulate natural pedalling dynamics and propel the vehicle efficiently. This is crucial as conventional pedalling power varies according to pedal orientation. The prototype also undergoes rigorous testing to evaluate its handling qualities, including predetermined manoeuvres to assess its performance. Ultimately, this research culminates in the development of a novel cargo bike with increased cargo capacity and improved handling, offering a promising solution to the challenges of last-mile delivery in urban environments.